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ELECTRICAL SAFETY INSPECTION REPORT

Penta Forth Apparels Ltd.

Mirer Changao, Ashulia, Savar, Dhaka, Bangladesh.

Factory List
Penta Forth Apparels Ltd.

Inspected by: Hemlal Dahal


Report Generated by: Hemlal Dahal

Inspected on 20 October 2015


ELECTRICAL SAFETY INSPECTION REPORT
Penta Forth Apparels Ltd.
1 INTRODUCTION
The Factory was surveyed for electrical safety by Woosun Energy and Construction Co., Ltd. (WEC).
The purpose of the survey was to identify significant electrical safety issues and to provide
recommendations for remediation based on applicable standards specified by the Accord.
The scope of this initial electrical safety inspection was limited to the review and identification of major
electrical safety issues. The inspection did not include identification of minor deficiencies, which would
be further addressed as part of follow up inspections.

2 LIMITATIONS
The information in this electrical safety inspection report was obtained during a visit to the facility and
during interviews with local factory management. It has not been possible to provide independent
verification for all the information and data collected, and, therefore, WEC cannot accept general
responsibility for omissions or errors arising from inaccuracies in this report from the information
obtained.
The findings and recommendations in this report are not intended to imply, guarantee, ensure or warrant
compliance with any government regulations. Additionally, the results do not imply in any way that
compliance with the findings or recommendations as stated in this report will eliminate all risks or
exposures not referred to in this report do not exist. Compliance with the findings and recommendations
stated in this report does not relieve the factory owner from obligation to comply with specific project
requirements, industry standards, or the provisions of any local government regulations.

3 DEFINITION
3.1 Time Frame
The amount of time being allocated based on the remediation work volume of the electrical issue
considering the feasibility and ideal status of materials, capital and working condition. Criticality and
priority level of the issue is not taken into consideration. It is bound only for the particular finding unless
mentioned typical, shall include the whole typical findings.

3.2 Priority Level


3.2.1 Electrical issues related to code violation and/or non-conformity with codes possessing immediate fire
hazard, direct threat to human safety, shall be considered as P1 Level of priority. The execution of
remediation works shall commence immediately without compromising with any other issues and must
strictly complete within the allocated remediation time frame. It shall include only the critical issues
3.2.2 Electrical issues related to code violation and/or non-conformity with codes, protection of electrical
switchgears and equipment, spatial arrangement and location of switchgears and equipment, design
and drawings, shall be considered as P2 Level of priority. The execution of remediation work of P2 shall
commence along with or soon after the P1 level remediation work has commenced. It shall include only
the moderately-critical issues
3.2.3 Electrical issues related to violation of code and/or non-conformity with codes, workmanship of
operation and maintenance and obsolete technology of electrical system, shall be considered as P3
Level of priority. The execution of remediation work of P3 shall commence along with or soon after the
P2 level remediation work has commenced. It shall include only the non-critical issues.
3.2.4 It doesnt take into consideration the remediation time frame and feasibility of remediation. It doesnt
take into consideration the capital, materials and working environment.

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Penta Forth Apparels Ltd. 1


4 GENERAL INFORMATION

Factory Name: Penta Forth Apparels Ltd.

Inspected on: October 20, 2015

Factory Address: Mirer Changao,


Ashulia,
Savar,
Dhaka,
Bangladesh.

Factory ID: 12241

Inspection Participants: Masud Choudhury


Chairman
Penta Forth Apparels Ltd.
880 1713450892
pentaforth@gmail.com

Rezaul Karim
Managing Director
Penta Forth Apparels Ltd.
880 1711560028
a2zbd@agni.com

Bekash Chandra Sarkar


Asst. Manager (HR & Compliance)
Penta Forth Apparels Ltd.
880 1913117994
pentaforth@gmail.com

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Penta Forth Apparels Ltd. 2


5 BUILDING DATA
5.1 Penta Forth Apparels Ltd. factory is established in 1 building plus utility buildings, and is rented by
the factory. A section of the 6 storied factory building is as shown in Figure 1.

The factory was constructed in 2012, production started in 2014, and during the inspection the
number of workers was approximately 385.

5.2 The building and shed utilization is as detailed below:

Number of Area of
Building Height of Building
Floors Building
Main Building 6 5,016 sq. m 19.70 m
Utility Shed 1 46 sq. m 4.57 m

Figure 1: Section of the factory building.

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Penta Forth Apparels Ltd. 3


Main Building
Ground floor: Bonded Warehouse, Finished goods, Office (15 Workers)
1st floor: Finishing section, Packing section, Office (55 Workers)
2nd floor: Sewing section, Office (250 Workers)
3rd floor: Sewing section (40 Workers)
4th floor: Temporary storage, Dining, Prayer
5th floor: Cutting section, Sample section (25 Workers)

Utility Shed
Ground floor: Generator, Substation

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Penta Forth Apparels Ltd. 4


5.3 Electrical System:
Penta Forth Apparels Ltd. gets its grid power from REB. There is 1 generator used as backup
power. The generator and transformer setup is as below.
The grid supply is tapped from 11kV OH line and delivered to the 250 kVA floor mounted
transformer through a HT cable which is protected by a DO fuse unit. The outputs from the
transformer and the standby diesel generator are fed to the factory electrical system through a
changeover switch.
The factory does not have a single line diagram of the electrical installations. Figure 2 shows the
electrical substation of the factory in the utility shed.

Figure 2: Electrical substation of Penta Forth Apparels Ltd. (Utility Shed).

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Penta Forth Apparels Ltd. 5


Transformer #1
Owner Factory owned
Location Floor mounted transformer in the substation
Transformer Type Oil immersed type
Arrangement 1 three-phase transformer
Single phase or 3 phase 3
Primary Voltage (kV) 11.0 kV
Secondary Voltage (kV) 0.42 kV
Capacity 250 kVA
Network System 3-P, 4-Wire

Generator #1
Generator Type Diesel
Capacity 150 kVA
Rated Voltage 400 V
Number of hours/day 2
Backup or Main supply Backup power

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Penta Forth Apparels Ltd. 6


5.4 Electrical Installation
The cabling systems in the factory are mostly supported in cable raceways made of aluminum
channels above the working tables. However, some sections of distributions are made through
surface PVC conduit and concealed conduit wires.
The lighting and cable raceway system in one of the production floors is as presented in Figure 3.

Figure 3: Electrical Installation on the factory floor.

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Penta Forth Apparels Ltd. 7


5.5 Operation and Maintenance:
The factory has no qualified engineers, 1 certified electrician, and 2 non-certified electrical staff on
its electrical maintenance team. The factory does not keep adequate maintenance records, and
maintenance of major equipment is carried out by the factory.

The maintenance record as presented by the factory officials is presented in Figure 4.

Figure 4: Maintenance records of the factory.

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Penta Forth Apparels Ltd. 8


6 LIGHTNING PROTECTION RISK ASSESSMENT
There is no adequate lightning protection system in the building, and there is no LPS drawing for the
system. The calculation of the risk index for lightning protection for this building is below.

Sl.no. Index category Index Figure

A Usage of Structure 6
B Type of construction 4
C Contents or consequential effects 5
D Degree of isolation 5
E Type of area and terrain 2
F Height of structure 8
G Lightning prevalence 21
Total index figure 51

Recommendation:
The total risk index figure is more than 40; hence a lightning protection system is required. An LPS
drawing must be drawn up

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Penta Forth Apparels Ltd. 9


7 FINDINGS AND RECOMMENDATIONS:
Table below summarizes the major electrical safety issues identified during the inspection.
Recommendations have been provided to address each issue. The implementation schedule shall
be developed by the factory to remediate each of the findings. The specific timing of improvements,
including any requested extensions due to design/installation constraints, shall be submitted to the
Accord for approval.

FINDING NO. E-1


CATEGORY: Design Drawings and Records
FINDING:
Electrical Single Line Diagram (SLD) is unavailable.

RECOMMENDATION:
Have a qualified engineer create an as-built electrical SLD mentioning all the required information, and get it
reviewed & approved by Accord.

PRIORITY: P-2
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-2


CATEGORY: Design Drawings and Records
FINDING:
Thermographic scanning of the entire electrical system has not been tested and recorded.

RECOMMENDATION:
Thermographic scanning for the entire electrical system must be performed on a bi-annual basis and
recorded.

PRIORITY: P-2
REMEDIATION TIMEFRAME: 8 Weeks

FINDING NO. E-3


CATEGORY: Design Drawings and Records
FINDING:
Transformer Oil Test report is unavailable.

RECOMMENDATION:
Check the transformer oil condition by performing oil test, this must be done twice a year and recorded.

PRIORITY: P-2
REMEDIATION TIMEFRAME: 8 Weeks

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Penta Forth Apparels Ltd. 10


FINDING NO. E-4
CATEGORY: Design Drawings and Records
FINDING:
Instruction for CPR (Cardiopulmonary Resuscitation) or Electrical shock restoration is not present.

RECOMMENDATION:
Hang this first aid and CPR instructions near all electrical equipment (LT panel, MDB, FDB, DB, SDB) on a
visible location.

PRIORITY: P-2
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-5


CATEGORY: Design Drawings and Records
FINDING:
Earth Pit resistance record is unavailable.

RECOMMENDATION:
Record earth pit resistances for all the earth pits, and do it once a year.

PRIORITY: P-2
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-6


CATEGORY: Design Drawings and Records
FINDING:
Insulation resistance test of power cables is not performed.

RECOMMENDATION:
Insulation resistance test of all power cables (up to Floor distribution board or SDB) must be performed in a
periodic manner and recorded.

PRIORITY: P-2
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-7


CATEGORY: Design Drawings and Records
FINDING:
No Maintenance records.

RECOMMENDATION:
Maintenance Manager or Safety Officer must keep accurate records and ensure that they reflect actual factory
day to day operations.

PRIORITY: P-2
REMEDIATION TIMEFRAME: 4 Weeks

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Penta Forth Apparels Ltd. 11


FINDING NO. E-8
CATEGORY: Design Drawings and Records
FINDING:
Electric safety training program is not conducted.

RECOMMENDATION:
Electrical safety training and awareness program for the electrical personnel and staff must be initiated and
recorded .

PRIORITY: P-2
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-9


CATEGORY: Service Line
FINDING:
Excess HT cables coiled and kept at the back of
transformer.

RECOMMENDATION:
HT cable bends shall be avoided such that no stress is
imposed on the terminating of the cable or insulation of
the cable. Rearrange the cables using cable tray/ladder
and latch the additional cable with the tray/ladder. Or lay
the cable coil underground as per standard cable laying
procedures.

PRIORITY: P-3
Excess HT coil in transformer room
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-10


CATEGORY: Service Line
FINDING:
HT cable passed through permanent wall not protected.

RECOMMENDATION:
The HT cable must be encased in steel/HDPE pipe
(conduit) when passed through the wall and seal the
unused openings after the passage of conduit by fire
rated materials.

PRIORITY: P-2
HT cable entering utility room
REMEDIATION TIMEFRAME: 2 Weeks

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Penta Forth Apparels Ltd. 12


FINDING NO. E-11
CATEGORY: Service Line
FINDING:
HT cable dropped on open wall not supported/protected.

RECOMMENDATION:
Install cable tray or steel conduit to support & protect HT
cable on wall. The cable must be firmly latched at
regular interval to the support provided.

PRIORITY: P-3
HT cable not protected
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-12


CATEGORY: Service Line
FINDING:
HT cable dropping from HT pole not supported.

RECOMMENDATION:
Install a ladder/pipe adequately supported with pole for
supporting the service cables in order to protect the
cables insulation from any physical damage.

PRIORITY: P-2
HT cable not supported
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-13


CATEGORY: Transformer
FINDING:
Transformer room congested.

RECOMMENDATION:
Maintain a sufficient working space (preferably 1.07
meters) around the transformer or assign a qualified
engineer to design a required transformer room
according to BNBC, Section-2.6.3.

PRIORITY: P-2
Congested transformer room
REMEDIATION TIMEFRAME: 12 Weeks

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Penta Forth Apparels Ltd. 13


FINDING NO. E-14
CATEGORY: Transformer
FINDING:
Transformer Silica gel is discoloured with empty oil cup.

RECOMMENDATION:
Replace silica gel by a new one; or dry it under sun and
reuse it, if colour regains and breather oil cup must be
filled with transformer oil to the required level as
instructed by the manufacturer.

PRIORITY: P-1
Deteriorated silica gel and empty oil cup
REMEDIATION TIMEFRAME: 1 Week

FINDING NO. E-15


CATEGORY: Generator
FINDING:
Generator exciter batteries not encased and placed on
floor.

RECOMMENDATION:
Encase the generator batteries and its charger in
metallic acid proof stand and insulate the battery
terminals. Establish a routine maintenance checklist for
the generator where the battery maintenance checklist
should be included.

PRIORITY: P-2
Generator batteries open and on floor
REMEDIATION TIMEFRAME: 2 Weeks

FINDING NO. E-16


CATEGORY: Distribution Boards & Panels
FINDING:
Neutral wires are bunched.

RECOMMENDATION:
Neutral wires must be terminated one by one at busbar
with proper sized cable lug.

PRIORITY: P-2
Bunched neutral wire
REMEDIATION TIMEFRAME: 4 Weeks

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Penta Forth Apparels Ltd. 14


FINDING NO. E-17
CATEGORY: Distribution Boards & Panels
FINDING:
Wires/cables not drawn swiftly/neatly inside a panel.

RECOMMENDATION:
Organize all the power cables or wires securely and
neatly. Install slotted PVC channels for routing wires and
cables inside the panel.

PRIORITY: P-2
Cables & wires not drawn swiftly
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-18


CATEGORY: Distribution Boards & Panels
FINDING:
Cables terminating at Panel/Changeover switch not
sufficiently supported (typical issue).

RECOMMENDATION:
Install cable trays or ladder to support the cables. The
cables must be drawn swiftly and securely latched at
regular interval on the support. Terminate the cables,
entering or exiting all panels and boards, with all the
supportive and protective accessories.

PRIORITY: P-2
Cables not supported
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-19


CATEGORY: Distribution Boards & Panels
FINDING:
No circuit diagrams on control panels and board (Typical
issue).

RECOMMENDATION:
Provide/hang circuit diagrams of panels/boards in every
panel. (Provide identification and warning notice in front
every electrical panel. Include voltage level on the notice
and any precautions if required for special case).

PRIORITY: P-2
Circuit diagram not hung on panels
REMEDIATION TIMEFRAME: 4 Weeks

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Penta Forth Apparels Ltd. 15


FINDING NO. E-20
CATEGORY: Distribution Boards & Panels
FINDING:
Panel doors not connected with earth bond (Typical
issue).

RECOMMENDATION:
Provide earth connection for body and doors of metallic
distribution boards using green cables preferably braid
so that the metallic door remains at zero potential all the
time.

PRIORITY: P-1
Door earth bond not provided
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-21


CATEGORY: Distribution Boards & Panels
FINDING:
Gland holes in panel left open (Typical issue).

RECOMMENDATION:
Provide cable gland according to the respective cable
size for cable entry and exit so that the cables are not
stressed on the sharp edges of the hole of panels.
Provide covers (of non-combustible material) if any
additional gap remains after installing cable glands.

PRIORITY: P-2
Gland holes open
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-22


CATEGORY: Distribution Boards & Panels
FINDING:
High temperature found in B-phase HRC fuse inside PFI
panel (Typical issue).

RECOMMENDATION:
Arrange periodic inspection & thermal scan to identify
the overloading, loose connection, unbalanced load,
faulty device which may cause the excessive heat-rise
and take action accordingly.

PRIORITY: P-1
High temperature in PFI panel devices
REMEDIATION TIMEFRAME: 2 Weeks

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Penta Forth Apparels Ltd. 16


FINDING NO. E-23
CATEGORY: Distribution Boards & Panels
FINDING:
HRC fuse bypassed by wire in PFI panel.

RECOMMENDATION:
Unrated wires should not be used in place of fuse.
Replace the defective HRC fuse with appropriately rated
HRC fuse.

PRIORITY: P-1
HRC fuse bypassed by wire
REMEDIATION TIMEFRAME: 2 Weeks

FINDING NO. E-24


CATEGORY: Distribution Boards & Panels
FINDING:
Inadequate rubber (insulation) mat on the working area
of distribution board/panel (typical issue).

RECOMMENDATION:
Provide electrical graded rubber mats with the
specifications of 650 V-protection and required area
(accommodating at least two people or depending on the
panels length.

PRIORITY: P-1
Inadequate insulation mat
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-25


CATEGORY: Distribution Boards & Panels
FINDING:
IPS installed below stair case.

RECOMMENDATION:
Panels/devices located below stairs must be relocated to
safe place. Existing device installed near exit may be
relocated as required by fire safety regulations.

PRIORITY: P-2
IPS below stairs
REMEDIATION TIMEFRAME: 4 Weeks

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Penta Forth Apparels Ltd. 17


FINDING NO. E-26
CATEGORY: Distribution Boards & Panels
FINDING:
Panel base plate not installed to allow cable entry
(Typical issue)

RECOMMENDATION:
Install base plate of the panel and make hole into it then
fit cable gland (required sized) for cable entry and exit to
the panel and seal all the unused openings by suitable
means to make the panel dust and vermin proof.

PRIORITY: P-2
No base plate
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-27


CATEGORY: Distribution Boards & Panels
FINDING:
Phase barrier/separators between different phases are
not installed or locally manufactured phase separators
used (Typical issue).

RECOMMENDATION:
Phase barriers between different phases must be
installed to avoid arc flashing. Standard separators
provided by the MCCB manufacturer must be used.

PRIORITY: P-2
No phase separators
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-28


CATEGORY: Distribution Boards & Panels
FINDING:
Electrical panel enclosure or body not connected to
earth (Typical issue).

RECOMMENDATION:
Panel enclosure including its door must be connected to
earth using green cables preferably earth braid so that
the metallic door remains at zero potential all the time.
Practice earth continuity test to insure earth continuity to
panel and loads enclosure and keep record.

PRIORITY: P-1
Panel body not earthed
REMEDIATION TIMEFRAME: 2 Weeks

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Penta Forth Apparels Ltd. 18


FINDING NO. E-29
CATEGORY: Cable & Cable Support
FINDING:
Power cable laid on concrete floor (Typical issue).

RECOMMENDATION:
The cables must be protected and supported by a
covered cable tray or ladder throughout its length. The
cables must be drawn, arranged swiftly & latched firmly
at a regular interval on the support provided.

PRIORITY: P-2
Cables laid directly on floor
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-30


CATEGORY: Cable & Cable Support
FINDING:
Generator output cables laid on floor without protection
and support.

RECOMMENDATION:
The cables must be protected and supported by a
covered cable tray or ladder throughout its length. The
cables must be latched firmly on the support provided.

PRIORITY: P-3
Generator cables not supported/protected.
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-31


CATEGORY: Boiler & Compressor Room
FINDING:
Wiring in flexible PVC conduit attached to boiler not
protected.

RECOMMENDATION:
Wires installed near/attached to boiler/generator body
must be protected from external heat & moisture by
metallic heat resistant conduit

PRIORITY: P-1
Wire in flexible PVC conduit attached to boiler
REMEDIATION TIMEFRAME: 2 Weeks

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Penta Forth Apparels Ltd. 19


FINDING NO. E-32
CATEGORY: Equipment & Machines
FINDING:
Large exhaust fans in production floors are directly
controlled by the MCB (Typical issue).

RECOMMENDATION:
Large exhaust fans must be connected through control
device such that it will not restart automatically when
power is restored.

PRIORITY: P-2
Large exhaust fans controlled by MCB
REMEDIATION TIMEFRAME: 4 Weeks

FINDING NO. E-33


CATEGORY: Earthing
FINDING:
Body/frame of electric boiler is not connected to earth.

RECOMMENDATION:
Ensure dedicated earthing connection for the body of
boiler (consult with your boiler supplier).

PRIORITY: P-1
Boiler body not earthed
REMEDIATION TIMEFRAME: 2 Weeks

FINDING NO. E-34


CATEGORY: Earthing
FINDING:
Earth pits are not identifiable (Typical issue).

RECOMMENDATION:
Clearly identify each earth pit, and mark it for periodic
maintenance purposes.

PRIORITY: P-2
Earth pit near substation
REMEDIATION TIMEFRAME: 2 Weeks

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Penta Forth Apparels Ltd. 20


FINDING NO. E-35
CATEGORY: Earthing
FINDING:
Generator body/frame is not connected to earth.

RECOMMENDATION:
Ensure minimum two earthing connection for generator
body (consult with your generator supplier).

PRIORITY: P-1
Generator body not earthed
REMEDIATION TIMEFRAME: 2 Weeks

FINDING NO. E-36


CATEGORY: Lightning Protection
FINDING:
Lightning Protection System(LPS) needed but has not
been installed.

RECOMMENDATION:
Design and Install LPS for your factory. Factory have to
submit LPS design to Accord before starting installation.

PRIORITY: P-1
Lightning Protection system missing
REMEDIATION TIMEFRAME: 8 Weeks

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Penta Forth Apparels Ltd. 21